Expanded Plastic Foam Construction Toy

Abstract

The disclosed technology relates to a construction toy made of expanded plastic foam extrusions. These extrusions are assembled with or without fasteners into a wide variety of configurations and optionally the extrusions are cut safely to a desired size.

Description

FIELD OF THE DISCLOSED TECHNOLOGY

The disclosed technology relates generally to building toys and more specifically to light weight toys made of expanded plastic foam such as polyethylene or polyurethane.

BACKGROUND

Children's blocks have forever been a source of creative play. Albert Einstein, Frank Lloyd Wright, Charles Eames, Buckminster Fuller and other thought leaders famously credit their childhood blocks as a valuable educational resource from their early youth. While playing with blocks is often an immersive experience, few sets of blocks allow for the construction of structures that are full size play sets. The risk of such a structure falling on a child has typically prevented this scale of immersive play set.

The logs or blocks are great for inside or outside play. While the playset is designed for the real world, a computer based playset for the computer world is one option. In this way, children can plan their designs on the computer, make them in the real world and play with them in either environment. Accordingly, there exists the need for building toys that allow for full size play sets without the risk of injury from falling pieces or injury from jumping off structures.

Accordingly, it is one objective of the disclosed technology to provide a toy building set having a hollow plastic extrusion log and the hollow plastic extrusion log comprising a front side and a backside. Also comprising a first end and a second end as well as topside and a bottom side. Each top and bottom side having a substantially flat planar surface and a plurality of apertures in the substantially flat planar surface and the apertures extending from an outer surface of the log to an inner hollow surface of the log.

The plurality of apertures extending the length of the top and bottom sides' substantially flat planar surface, wherein the log is stackable by aligning the bottom side of said log with an adjacent topside of a log to thereby construct the desired lightweight self-supporting structure. The log is made of expanded polyethylene foam.

It is a further objective of the disclosed technology to have toy building set with a hollow plastic extrusion log wherein the log front side is curved and the backside is a substantially flat planer surface having a plurality of apertures extending from the outer surface of the log to the inner hollow surface of the log. A plurality of apertures extends the length of the backside of said log.

Another advantage of the disclosed technology is a toy building set wherein at least two adjacent logs are removably attached to a connector. The connector is multidirectional thus enabling the adjacent log to be rotated toward a specific direction and configured to interchangeably attach to each log. Wherein, the log is stackable with adjacent logs and connectors are placed between and inside apertures of adjacent logs to thereby construct the desired lightweight self-supporting structure.

According to some embodiments, the toy building set where the connector is removably attached to at least two adjacent logs through the apertures of the logs. Also, wherein the connectors comprise a central planar disk having two opposite ends from central planar disk and opposite ends further comprise distal planar disks. The distal planar disks pass through the apertures and into the hollow area of the logs to form an interference fit in the apertures with the central disk remaining outside of the apertures of the logs. Thus, the connector remains removably attached to the logs until desired removal.

It is also an objective of the disclosed technology to provide a connector where the two opposite ends from a central planar disk comprises a shaft shaped as a straight line S. Also, wherein the distal planer disks have an oval shape and the plurality of apertures in the log are circle shapes and passing of the distal planer disk through an aperture requires pressure and angling the distal planar disk through the aperture such that the connector overlaps a portion of the distal planar disk with a portion of the hollow inside of the log and thus secured until desired removal.

The distal planer disks of the connector have an oval shape and the plurality of apertures in the log have a matching oval shape; and wherein passing of the distal planer disk through an aperture requires positioning the distal planar disk shape to match the aperture shape. After the planar disk is through said aperture the connector is turned ninety degrees around an axis perpendicular to the distal planar disk such that the connector overlaps a portion of the distal planar disk with a portion of the hollow inside of the log and thus secured until desired removal. The connector is made with injection molded plastic.

Pluralities of apertures of a log are at fixed measurable intervals to each other, and the interval apertures determine a length by counting the apertures. A log is sawed into a plurality of smaller logs when a cutting edge provides tension onto a log such that bubbles of the plastic extrusion burst as the cutting edge go through the log.

Another objective is to have a saw comprising support for a dull cutting edge for cutting a log, and the dull cutting edge provides tension such that when the cutting edge is passed through the log, bubbles of the plastic extrusion burst as the saw passes through the plastic extrusion. The cutting edge of the saw comprises one of the following: plastic, metal, string; or wire.

In another objective there is a miter having vertical miter protrusions for placement of the log and a perpendicular slot in the vertical miter protrusions for placement of the cutting edge of the saw. When the cutting edge and the log are very stable for cutting the log.

In a further objective, a log front side and back side are both curved or the front side and back side are substantially flat planer surfaces having a plurality of apertures extending from the outer surface of the log to the inner hollow surface of the log. The plurality of apertures extends the length of the backside and the front side of the log.

In yet another objective, two adjacent logs are removably attached by a U connector and a log is stackable with an adjacent log and a U connector is placed on a portion of at least one end of a log and an adjacent log. The U connector uses spring tension on the two adjacent logs and remains removably attached to the logs until desired removal. Alternatively, the U connector has two ends and the two ends of the U connector further comprise protrusion that face each other such that the two ends are placed in the hollow of two adjacent logs and the two protrusions are placed in the apertures of the two adjacent logs. The U connector utilizes spring tension on the two adjacent logs and remains removably attached to the logs until desired removal.

Advantageously, the log apertures are shaped as one of the following: circle; two slits forming a plus sign; center circle superimposed on two slits; an oval; or an ellipse.

In another objective, the toy building set further comprises a spike having a first end with a flat head and a second end with a bulbous detail. The bulbous detail of a spike passing through a log aperture or a plurality of log apertures to the hollow area of a log such that the bulbous detail of the spike forms an interference fit in the aperture of a log and said spike flat head is sized to remain outside of a log.

It is also an objective to have a toy building set also comprising a flat plate fastener having an elongated oval planar shape with a first end having a portal there through and a second end having a portal there through.

A spike is passed through a portal of the flat plate fastener and a log apertures to the hollow area of a log such that the bulbous detail of the spike forms an interference fit in the aperture of the log and the spike flat head is sized to remain outside of the portal of the flat plate connector and of the log. Two adjacent logs are thus connected with apertures not facing each other.

In yet another objective, a toy building set having a hollow plastic extrusion log and the hollow plastic extrusion log comprising; a front side and a back side; a first end and a second end; a top side and a bottom side; each top and bottom side having a plurality of apertures in the extending from an outer surface of the log to an inner hollow surface of the log. The log is stackable by aligning the bottom side of said log with adjacent topside of a log to thereby construct the desired lightweight self-supporting structure.

In another advantage, the toy building set further comprising a fabric having apertures to accept and attach the fabric to a log or plurality of logs.

Also advantageous is a method of using a toy building set to build play sets comprising the following steps. First, selecting a plurality of logs, each log comprising; a front side and a back side; a first end and a second end; a top side and a bottom side; each top and bottom side having a substantially flat planar surface and a plurality of apertures in the substantially flat planar surface. The apertures extend from an outer surface of the log to an inner hollow surface of the log and extending the length of the top and bottom sides' substantially flat planar surface.

Second, determining the length of the logs needed for building a toy structure and determining what logs need to be cut. Third, counting the number of apertures on the logs needing to be cut to determine where to cut the logs and sawing the logs to appropriate sizes. Then placing one of the pluralities of logs on the ground or on a support horizontally with on of the substantially flat planar surfaces facing the ground or support.

Placing a connector or plurality of connectors into the apertures of the log placed on the ground or support and determining which of the plurality of logs is a second log to be placed on top of the log already placed. Then placing the second log, wherein the second log is stackable on the log already place and connectors are between and inside apertures of adjacent apertures of the logs.

Another method continues with a plurality of adjacent logs and connectors are placed between and inside apertures of adjacent logs to thereby construct the desired lightweight self-supporting structure.

In a final objective, a method of using a toy building further comprising the following steps of selecting a log and determining the length of the log needed. Then placing a miter on a flat surface and counting the apertures of the log. Placing the log in the miter the correct distance from the end to cut the log and then placing a saw in a slot of the miter to accept the saw. Finally sawing the log.

SUMMARY OF THE DISCLOSED TECHNOLOGY

Aspects of the disclosed technology, according to some embodiments thereof, addresses an unfulfilled need in the prior art by providing a construction toy with hollow extrusions of expanded plastic foam with a profile to improve stack ability. The hollow extrusion further being easily cut with a toy saw so that the user can construct playsets and structures of their own design. The toy is not only easy to use but educational. Children can plan and build structures in three dimensions that visualize their own design. The hollow extrusions provide a lightweight; soft, structural material that allows for safely built play structures that reach over a child's head without concern for injury.

Certain embodiments of the present invention may include some, all, or none of the above advantages. Further advantages may be readily apparent to those skilled in the art from the figures, descriptions, and claims included herein. Aspects and embodiments of the invention are further described in the specification herein below and in the appended claims.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. In case of conflict, the patent specification, including definitions, governs. As used herein, the indefinite articles “a” and “an” mean “at least one” or “one or more” unless the context clearly dictates otherwise.

The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, but not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other advantages or improvements.

BRIEF DESCRIPTION OF THE FIGURES

Some embodiments of the invention are described herein with reference to the accompanying figures. The description, together with the figures, make apparent to a person having ordinary skill in the art how some embodiments may be practiced. The figures are for the purpose of illustrative description and no attempt is made to show structural details of an embodiment in more detail than is necessary for a fundamental understanding of the invention. For the sake of clarity, some objects depicted in the figures are not to scale.

FIG. 1a illustrates a perspective view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 1b illustrates an end view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 1c illustrate a front or back view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 1d illustrate a top or bottom view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 2a illustrates a perspective view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 2b illustrates a top or bottom view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 2c illustrates back view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 2d illustrates an end view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 2e illustrates a front view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 3a illustrates a perspective view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 3b illustrates a top or bottom view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 3c illustrates an end view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 3d illustrates front or back view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 4 illustrate building log of a toy building set according to some embodiments of the current technology.

FIG. 5 illustrate building log of a toy building set according to some embodiments of the current technology.

FIG. 6a illustrates a perspective view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 6b illustrates a top or bottom view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 6c illustrates an end view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 6d illustrates a side view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 7a illustrates a perspective view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 7b illustrates a top or bottom view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 7c illustrates an end view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 7d illustrates a side view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 8a illustrates a perspective view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 8b illustrates a top or bottom view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 8c illustrates an end view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 8d illustrates a side view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 9a illustrates a perspective view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 9b illustrates a top or bottom view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 9c illustrates an end view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 9d illustrates a side view of a building log of a toy building set according to some embodiments of the current technology.

FIG. 10a shows a perspective view of a connector of a toy building set according to some embodiments of the current technology.

FIG. 10b shows a top or bottom view of a connector of a toy building set according to some embodiments of the current technology.

FIG. 10c shows a side view of a connector of a toy building set according to some embodiments of the current technology.

FIG. 11a illustrates a perspective view of a connector of a toy building set according to some embodiments of the current technology.

FIG. 11b illustrates a top or bottom view of a connector of a toy building set according to some embodiments of the current technology.

FIG. 11c illustrates an end view of a connector of a toy building set according to some embodiments of the current technology.

FIG. 11d illustrates a side view of a connector of a toy building set according to some embodiments of the current technology.

FIG. 11e illustrates a section view of FIG. 11d of a connector of a toy building set according to some embodiments of the current technology.

FIG. 12a illustrates a perspective view of a connector of a toy building set according to some embodiments of the current technology.

FIG. 12b illustrates a top or bottom view of a connector of a toy building set according to some embodiments of the current technology.

FIG. 12c illustrates an end view of a connector of a toy building set according to some embodiments of the current technology.

FIG. 12d illustrates a side view of a connector of a toy building set according to some embodiments of the current technology.

FIG. 13a illustrates a perspective view of a connector of a toy building set according to some embodiments of the current technology.

FIG. 13b illustrates a top or bottom view of a connector of a toy building set according to some embodiments of the current technology.

FIG. 13c illustrates an end view of a connector of a toy building set according to some embodiments of the current technology.

FIG. 13d illustrates a side view of a connector of a toy building set according to some embodiments of the current technology.

FIG. 14 is a perspective view of a connector and logs of a toy building set connecting two logs according to some embodiments of the current technology.

FIG. 15 shows a connector and logs of a toy building set connecting two logs according to some embodiments of the current technology.

FIG. 16a shows a perspective view of a connector of a toy building set according to some embodiments of the current technology.

FIG. 16b shows a side view of a connector of a toy building set according to some embodiments of the current technology.

FIG. 16c shows a one-end view of a connector of a toy building set according to some embodiments of the current technology.

FIG. 16d shows a top or bottom view of a connector of a toy building set according to some embodiments of the current technology.

FIG. 16e shows a second end view of a connector of a toy building set according to some embodiments of the current technology.

FIG. 17 shows a connector and logs of a toy building set connecting logs according to some embodiments of the current technology.

FIG. 18a shows a perspective view of a saw of a toy building set according to some embodiments of the current technology.

FIG. 18b shows top view of a saw of a toy building set according to some embodiments of the current technology.

FIG. 18c shows an end view of a saw of a toy building set according to some embodiments of the current technology.

FIG. 18d shows a side view of a saw of a toy building set according to some embodiments of the current technology.

FIG. 18e shows a bottom view of a saw of a toy building set according to some embodiments of the current technology.

FIG. 18f shows a second side view of a saw of a toy building set according to some embodiments of the current technology.

FIG. 18g shows a perspective view of a second side of a saw of a toy building set according to some embodiments of the current technology.

FIG. 19a shows a perspective view of a miter for use with a saw of a toy building set according to some embodiments of the current technology.

FIG. 19b shows a top view of a miter for use with a saw of a toy building set according to some embodiments of the current technology.

FIG. 19c shows an end view of a miter for use with a saw of a toy building set according to some embodiments of the current technology.

FIG. 19d shows a side view of a miter for use with a saw of a toy building set according to some embodiments of the current technology.

FIG. 20 illustrates a log, saw and miter before cutting of a log of a toy building set according to some embodiments of the current technology.

FIG. 21 illustrates a log, saw and miter during cutting of a log of a toy building set according to some embodiments of the current technology.

FIG. 22a illustrates a perspective view of a right angle fastener of a toy building set according to some embodiments of the current technology.

FIG. 22b illustrates a side view of a right angle fastener of a toy building set according to some embodiments of the current technology.

FIG. 22c illustrates an end view of a right angle fastener of a toy building set according to some embodiments of the current technology.

FIG. 23 shows a connector, right angle fastener and logs of a toy building set connecting logs according to some embodiments of the current technology.

FIG. 24a illustrates a perspective view of a flat plate fastener of a toy building set according to some embodiments of the current technology.

FIG. 24b illustrates a side view of a flat plate fastener of a toy building set according to some embodiments of the current technology.

FIG. 24c illustrates an end view of a right angle fastener of a toy building set according to some embodiments of the current technology.

FIG. 24d illustrates a front or back view of a flat plate fastener of a toy building set according to some embodiments of the current technology.

FIG. 25a illustrates a perspective view of a spike of a toy building set according to some embodiments of the current technology.

FIG. 25b illustrates a side view of a spike of a toy building set according to some embodiments of the current technology.

FIG. 25c illustrates a flat head view of a spike of a toy building set according to some embodiments of the current technology.

FIG. 25d illustrates an alternate flat head view of a spike of a toy building set according to some embodiments of the current technology.

FIG. 26 shows a spike, flat plate fastener and logs of a toy building set connecting logs according to some embodiments of the current technology.

FIG. 27 shows a connector, flat plate fastener and logs of a toy building set connecting logs according to some embodiments of the current technology.

FIG. 28 illustrates a base for placement of a log vertically of a toy building set according to some embodiments of the current technology.

FIG. 29 illustrates a spike base for placement of a log vertically of a toy building set according to some embodiments of the current technology.

FIG. 30 illustrates a corner connection of a toy building set according to some embodiments of the current technology.

FIG. 31 illustrates a corner connection for connecting two logs of a toy building set according to some embodiments of the current technology.

FIG. 32a shows a perspective view of a panel of a toy building set according to some embodiments of the current technology.

FIG. 32b shows a side view of a panel of a toy building set according to some embodiments of the current technology.

FIG. 32c shows a bottom view of a panel of a toy building set according to some embodiments of the current technology.

FIG. 32d shows an end view of a panel of a toy building set according to some embodiments of the current technology.

FIG. 32e shows a top view of a panel of a toy building set according to some embodiments of the current technology.

FIG. 33 illustrates the connection of panels of a toy building set according to some embodiments of the current technology.

FIG. 34a illustrates a perspective view of a corner panel connector of a toy building set according to some embodiments of the current technology.

FIG. 34b illustrates an end view of a corner panel connector of a toy building set according to some embodiments of the current technology.

FIG. 34c illustrates a first side view of a corner panel connector of a toy building set according to some embodiments of the current technology.

FIG. 34d illustrates a second side view of a corner panel connector of a toy building set according to some embodiments of the current technology.

FIG. 35 illustrates a corner panel connector for connecting two ends of panels of a toy building set according to some embodiments of the current technology.

FIG. 36 a partial perspective view of logs forming a corner of a log cabin type building using connectors of a toy building set according to some embodiments of the current technology.

FIG. 37 a perspective view of logs forming a corner of a log cabin type building after connection with connectors of a toy building set according to some embodiments of the current technology.

FIG. 38a a perspective view of a castle built with the toy building set according to some embodiments of the current technology.

FIG. 38b a top view of a castle built with the toy building set according to some embodiments of the current technology.

FIG. 38c a side view of a castle built with the toy building set according to some embodiments of the current technology.

FIG. 39a a perspective view of a log cabin built with the toy building set according to some embodiments of the current technology.

FIG. 39b a second perspective view of a log cabin build with the toy building set according to some embodiments of the current technology.

FIG. 40 a perspective view of a sailing ship during construction built with the toy building set according to some embodiments of the current technology.

A better understanding of the disclosed technology will be obtained from the following detailed description of the preferred embodiments, taken in conjunction with the drawings and the attached claims.

DETAILED DESCRIPTION OF SOME EMBODIMENTS

The ensuing detailed description provides explanation of various aspects of the disclosed technology. The purpose of this explanation is to provide a thorough understanding of the different aspects of the disclosed technology. This description is not intended to limit the scope, applicability, or configuration of the disclosed technology. It will also be apparent to one skilled in the art that the disclosure may be practiced without specific details being presented herein. Various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the disclosed technology as set forth in the appended claims. Furthermore, well-known features may be omitted or simplified for clarity.

To aid in describing the describing the disclosed technology, directional terms may be used in the specification and claims to describe portion of the present technology (e.g upper, lower, left, right, etc.) These directional definitions are merely intended to assist in describing and claiming the disclosed technology and are not intended to limit the disclosed technology in any way. In addition, reference numerals that are introduced in the specification in association with a drawing figure may be repeated in one or more subsequent figure without additional description in the specification, in order to provide context for the other features.

The term “plurality” as used herein, means more than one.

The terms “noodle”, “log” and “block” as used herein are interchangeable.

The term “substantially flat planar surface” as used herein is defined as a flat section along the length of the side of a log and from 25 percent to 100 percent of the width of a side of the log.

The term “Fixed” connection as used herein is defined as one which is expected to or does cause damage to one of the parts described when removed.

The term “Removable” as used herein is defined as able to connect and disconnect repeatedly (>6 times) without causing damage to a connector piece or parts being connected.

The term “Pivoted” as used herein is defined as a linkage that allows at least one degree of freedom of movement similar to a hinge between connected logs or parts.

Expanded polyethylene extrusions provide a lightweight, soft, structural material that can allow children to safely build play structures of their own imaginations that reach over their heads without concern of injury. The blown polyethylene hollow extrusions interlock with simple connector designs that allow a child to assemble log cabins, forts, castles, boats and other imaginative structures quickly and easily with no tools other than a saw, if desired.

According to an aspect of some embodiments, there is provided a log 100. Log 100 of FIG. 1 is a blown or expanded hollow extrusion of plastic. One option is a circular extrusion of plastic. Log 100 is an elongated and typically hollow cylinder 140 with flattened exterior planar sections or substantially flat planar surface 110. The substantially flat planar surfaces 110 being opposite one another on log 100. Log 100 in some embodiments, also having two sides 120, being the radius of a circle.

In some embodiments logs 100 are made of polyethylene foam. Some embodiments of log 100 have apertures 130. In some embodiments, apertures 130 pass through from the exterior of log 100 to an interior hollow 140 of log 100, located on the substantially flat planar surface 110. Flat planar surface 110 in some embodiments comprises one or more of the four sides of log 100 and flat section 110 is 25 percent to 100 percent of the widths of the side of log 100.

Although apertures 130 need not be at regular intervals, placement of apertures 130 at regular intervals facilitates measurement without the use of a measuring tool. The ability to measure without a measuring tool is convenient when a certain size of log 100 is required for a play set. The regular intervals of apertures 130 provide a consistently measured length obviating the need for a measuring tool.

In some embodiments, apertures 130 of log 100 extend the full length of log 100. In some embodiments, the apertures 130 of log 100 do not extend the full length of log 100, and a portion of flat planar surface 110 at the end of log 100 does not have apertures 130. Logs 100, in some embodiments, have no flat surface; however, do have apertures 130 at regular intervals (not shown).

The apertures 130 allow fixed, pivoted, and/or removable connections between two logs 100. The logs 100 are malleable such that they can be bent from a straight shape to an acute angle shape and held there by connection with other logs, connectors or fasteners.

The log's 100 planar sections 110 enable stacking of logs 100 such that logs 100 sit in a stable manner, one on top of the other, even without the aid of further connectors. One of many building options is to configure logs 100 in the same stacking configuration as one would associate with crisscrossed logs seen in log cabin construction.

Tied string or adhesive tape is also an option for connecting a plurality of logs 100. Connectors 200, (See FIGS. 10-13) in some embodiments, are injection molded plastic, removably attached to logs 100 through apertures 130. For safety reasons, connectors 200 need to pass the toy industry standard test geometries of the Small Part Test. Toy industry studies have established that a part that cannot be wholly contained in a truncated cylinder with a 1.7 inches diameter achieves the safety level to pass the above tests.

FIG. 2 illustrates a log 100b according to some embodiments. Log 100b is very similar to log 100; however, a third flat planar surface 110b is added to allow fasteners to fasten the logs together in a greater variety of configurations. Furthermore, the third flat planar surface of FIG. 2c is smaller in area than the other two flat planar surfaces of FIG. 2b.

FIG. 3 illustrates log 100b now having apertures 130c shaped differently than apertures 130. Similarly, FIG. 4 has log 100d with apertures 130d shaped as two slits forming a plus sign. While FIG. 5 has a log 100e having apertures 130e, with a center circle superimposed on two slits.

FIG. 6 shows log 100f that in some embodiments has flat planar surfaces 115f on front, back, top and bottom sides of log 100f. In some embodiments, the apertures 130f are on only on two opposing sides, and the remaining two sides of log 100f have no apertures. In some embodiments, the apertures 130f are on all sides of log 100f.

Log 100g of FIGS. 7 and 8 are similar to log 100f except they are now bisected lengthwise. Log 100g, having apertures 130g on only one side is illustrated by FIG. 7. Log 100g, having apertures 130g on all sides, is illustrated by FIG. 8.

FIG. 9 shows log 100h, having flat planar surface 110h on three sides, similar to FIG. 2. FIG. 9 illustrates that, in some embodiments, flat planar surfaces 110h on all three sides of log 100h are the same dimension. In some embodiments, all three flat planar surfaces 110 are of different area width of the sides. In some embodiments, all three flat planar surfaces 110h have apertures 130h. The remaining side 135h is curved.

FIGS. 10a, 10b and 10c all illustrate a male connector 200. A central planar disk 210 bisects each of the opposite ends 220. Ends 220 point in opposite directions, outward from the central planar disk 210, with each end designed to pass through an aperture 130 of a log or logs 100 and/or fastener portal 510 of fastener 500 and 500a (See FIGS. 22 and 24). There are pluralities of apertures 130 along each log 100 where connectors 200, when placed, allow the axis of logs 100 to be angled relative to each other and not limited to right angle connections.

Now onto FIG. 11, which illustrates male connector 200a, having a central planar disk 210a that bisects each of the opposite ends 220a and further comprising two distal planar disks 225a. In some embodiments, male connector opposite ends 220a comprise shaft 230a, having the shape of an S with the center of the S being a straight line as seen in FIG. 11e. This S straight-line shape of 230a requires less material than an X configuration, resulting in reduced cost of manufacturing.

FIG. 12 is similar to FIG. 11 having a connector 200b with central planar disk 210b that is now oval shaped and centrally bisected by each of the opposite ends 220b. Connector 200b further comprises distal oval shaped planar disks 225b not centered to supports 230b. FIG. 13 is similar to FIG. 11, now having a connector 200c with oval shaped distal planar disks 225c centered on supports 230c.

The term “oval” as used in relation to the connectors means a shape with two radiuses with parallel sides. Also the term “ellipse”, as used herein, means a shape with a major and minor diameter and no radius.

One option to connect adjacent logs 100 with connectors 200 is illustrated in FIG. 14. FIG. 15 illustrates a distal planer disk connector 200c and logs 100c with oval shaped apertures 130c. The passing of the connector 200c through an aperture 130c requires positioning the distal planar disk shape 225c to match the aperture shape 130c. Thus, after the planar disk 225c is through the aperture 130c the connector 200c is turned ninety degrees around an axis perpendicular to the distal planar disk 225c, such that the connector 200c overlaps a portion of the distal planar disk 225c with a portion of the hollow 140 inside of the log 100c and is thus secured until desired removal.

Now onto FIGS. 16 and 17, U shaped connector 300 in some embodiments, has two ends 310 with protrusions 320 that face each other. In some embodiments, U shaped connector 300 has two ends 310 and no protrusions (not shown). The U connector 300 utilizes spring tension to hold two adjacent logs 100 together. Log 100 stacks on adjacent log 100.

FIG. 17 shows U connector 300 placed on a portion of at least one end 330 of log 100h and adjacent log 100h, such that ends 310 are placed in a hollow section 140 of two adjacent logs 100h and the two facing protrusions 320 are placed in apertures 130h. Whereby U connector 300 utilizes spring tension on the two adjacent logs 130h and remains removably attached to logs 100h until desired removal. Plastic and metal are two of many options from which U connector 300 are made.

A saw 400 and miter 450 as seen in FIGS. 18 to 21 is optionally used to cut any of logs 100 to size. Saw 400 has a narrow and planar plate 410, and in some embodiments, rounded backsides with wider handle 420. In some embodiments, a string or metal wire (not shown) is held between the ends of the wider handle 420 used to cut the logs 100. Saw 400 will cut log 100 by bursting the thousands of soft plastic bubbles. This method of cutting logs 100 results in minimal mess, i.e. such as saw dust with other materials, and also makes accidentally cutting a finger more difficult. In some embodiments, saw 400 will have teeth and in other embodiments, saw 400 will not have teeth but rather a non-sharp straight edge. The straight side of saw 400 is optionally made of plastic or metal.

FIGS. 19 to 21 illustrate miter 450. Miter 450 has a flat bottom 455 for resting log 100 for support. Miter 450 further comprises vertical portions 460 that each have a slot 475 through which saw 400 is aligned to help ensure saw 400 is perpendicular to log 100 during cutting. In some embodiments, log 100 is compressed when cut by the saw 400 guided by the miter 450. Other well-known miter systems may also be used.

Right angle fastener 500 is illustrated in FIG. 22. Right angle fasteners 500 are rigid and fixed in shape, having portals 510 with one portal 510 oriented at a 90-degree angle to the other. Portals 510 are used to pass connectors 200 there through as well as through an aperture 130 on a log 100. FIG. 23 illustrates two logs 100 attached at 90-degree angles to one another. That is, the planar section 110 of one log 100 is at a 90-degree angle to the planer section 110 of another log 100. The right angle fastener 500 attaches to an aperture 130 of each log 100 with a connector 200 passing through each log 100 and each portal 510 of right angle fastener 500.

FIG. 24 illustrates a flat fastener 500a. Flat fastener 500a has portals 510a. When logs 100 are attached and apertures 130 are not facing each other, a flat fastener 500a facilitates connection of logs 100, see FIGS. 26 and 27. Here the portals 510a of flat fastener 500a work when the logs 100 are aligned in the same two-dimensional plane to adjacent logs 100 to hold them in place together. Connectors 200 are one option to use; with connector 200 going through portal 510a and apertures 130 of log 100.

In some embodiments, spike connector 600 (as seen in FIGS. 25 and 26) is used to go through apertures 130 and/or portals 510a. Spike 600 having a flat head 610 and bulbous end 620. FIG. 25d showing the flat head 610 with a Phillips head portion.

A base 700 for use when logs 100 are supported on end by hollow 140 instead of a flat planar surface is illustrated by FIG. 28. Similarly, FIG. 29 illustrates a spike base 700a. In some embodiments, spike section 710a sticks into the ground and upper support section 720a supports the hollow 140 of log 100. Spike base 700a optionally includes at least one tether link 730a for tying items to or to aid in removal from the ground.

FIGS. 30 and 31 illustrate corner connector 700b for use in hollow 140 of logs 100. Providing even another way to build with the toy building set.

Panel 800 and corner panel connectors 850, as seen in FIGS. 32 to 35, are also interconnecting building structures in some embodiments of the current disclosed technology. Panels 800 having a bottom groove 810 and elongated protrusions 820 for interconnecting with each other, such that the protrusion 820 of one panel 800 fits into the groove 810 on the bottom side of another panel 800. Panels 800 further comprise side slots 830 for use with corner panel connectors 850.

Fabric or material elements (see FIG. 40) are optional additions to the toy building set of the currently disclosed technology. Fabric is optionally used for a roof, sail or any other play set building needs. There are a few options for the material element of the toy building set. A plastic foam extrusion on one side and material on other is one option for such a fabric. Another option is EVA material similar to a yoga mat. Finally, plastic foam extrusion woven inside of a fabric is an option. The fabric, in some embodiments, includes apertures of the same shape and size as log apertures 130, such that logs 100 and fabric are removably attached to each other and in some embodiments, using connector 200.

Using the devices of the disclosed technology, one can build a log cabin (FIGS. 36, 37 and 39) by stacking logs 100 at right angles using connectors 200 alone. Logs 100 are cut to size in order to fit as shown in the drawings. Other items such as castles and sailing ships can also be built as seen in FIGS. 38 and 40. Log cabins, forts, castles and boats are built quickly and easily assembled with no tools except optionally a saw 400.

In particular, in the sailing ship of FIG. 40 one can see long logs 100, which bend past short logs 100 internal to the ship causing the long logs to bend as they approach the bow of the ship. A combination of right angle fasteners 500, flat fasteners 500a, and connectors 200 are used. Logs 100 and fasteners 200 are all that are needed if logs have apertures 130 on at least three sides. Flat fasteners 500, inserted between two logs 100 extending horizontally, support the cannons. The flat fastener 500 “sticks out” from logs 100 and is attached underneath the cannon, cut to length with saw 400 in some embodiments of the disclosed technology.

In some alternative embodiments, any other shape made from expanded plastic is used as the building blocks or logs 100. Furthermore, these building blocks or logs 100 can interlock directly without the use of connectors, in a range of ways. These ways include, but are not limited to; tongue and groove type interlocks.

In short, one can use the tools and embodiments described to connect logs 100 in multiple ways. The logs 100 have flat planar surfaces 110 with apertures 130 and hollow inner areas 140. The apertures 130 and inner areas 140 can be used to connect various straight, right-angled, and other connectors 200 while the log extrusions 100 themselves can be cut to any desired size. As such, one can create a next to limitless amount of varied creations.

While the disclosed technology has been taught with specific reference to the above embodiments, a person having ordinary skill in the art will recognize that changes can be made in form and detail without departing from the spirit and the scope of the disclosed technology. The described embodiments are to be considered in all respects only as illustrative and not restrictive. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. Combinations of any of the methods, systems, and devices described herein above are also contemplated and within the scope of the disclosed technology.

variety of configurations and optionally the extrusions are cut safely to a desired size.

Claims

1. A toy building set having a hollow plastic extrusion log and said hollow plastic extrusion log comprising;

a front side and a back side;

a first end and a second end;

a top side and a bottom side;

each top and bottom side having a substantially flat planar surface;

a plurality of apertures in the substantially flat planar surface and the apertures extending from an outer surface of the log to an inner hollow surface of the log;

said plurality of apertures extending the length of the top and bottom sides substantially flat planar surface;

wherein the log is stackable by aligning the bottom side of said log with an adjacent top side of a log to thereby construct the desired lightweight self-supporting structure.

2. A toy building set having a hollow plastic extrusion log of claim 1, wherein the log front side is curved and the back side is a substantially flat planer surface having a plurality of apertures extending from the outer surface of the log to the inner hollow surface of the log; and

the plurality of apertures extend the length of the back side of said log.

3. A toy building set of claim 1 wherein at least two adjacent logs are removably attached to a connector; and

the connector is multidirectional thus enabling the adjacent log to be rotated toward a specific direction and configured to interchangeably attach to each log;

wherein the log is stackable with adjacent logs and connectors are placed between and inside apertures adjacent logs to thereby construct the desired lightweight self-supporting structure.

4. The toy building set of claim 3 wherein the connector is removably attached to at least two adjacent logs through the apertures of the logs.

5. The toy building set of claim 4, wherein the connector comprises a central planar disk having two opposite ends from central planar disk;

and opposite ends further comprise distal planar disks;

wherein the distal planar disks pass through the apertures and into the hollow area of the logs to form an interference fit in the apertures with the central disk remaining outside of the apertures of the logs; thus the connector remains removably attached to the logs until desired removal.

6. The connector of claim 5, wherein the two opposite end from a central planar disk comprises a shaft shaped as a straight line S.

7. The connector of claim 5, wherein the distal planer disks have an oval shape and the plurality of apertures in the log are circle shapes; and wherein passing of the distal planer disk through an aperture requires pressure and angling the distal planar disk through the aperture such that the distal planar disk overlaps a portion of the hollow inside of the log and thus secured until desired removal.

8. The connector of claim 5, wherein the distal planer disks have an oval shape and the plurality of apertures in the log have a matching oval shape; and wherein passing of the distal planer disk through an aperture requires positioning the distal planar disk shape to match the aperture shape; whereby after the planar disk is through said aperture the connector is turned ninety degrees around an axis perpendicular to the distal planar disk such that the connector overlaps a portion of the hollow inside of the log and thus secured until desired removal.

9. The log of claim 1 wherein the plurality of apertures are at fixed measurable intervals to each other, and the interval apertures determine a length by counting the apertures.

10. A log of claim 1, wherein a log is sawed into a plurality of smaller logs when a cutting edge provides tension onto the log such that bubbles of the plastic extrusion burst as the cutting edge goes through the log.

11. A saw having support for a dull cutting edge for cutting a log of claim 1, wherein

a. the dull cutting edge provides tension such that when the cutting edge is passed through the log, bubbles of the plastic extrusion burst as the saw passes through the plastic extrusion;

b. wherein the cutting edge comprises one of the following: plastic, metal, string, or wire.

12. The saw of claim 11 further comprising a miter having vertical miter protrusions for placement of the log and a perpendicular slot in the vertical miter protrusions for placement of the dull cutting edge of the saw, such that the cutting edge and the log are very stable for cutting the log.

13. A toy building set having a hollow plastic extrusion log of claim 1, wherein the log front side and back side are both curved.

14. A toy building set having a hollow plastic extrusion log of claim 1, wherein the front side and back side are substantially flat planer surfaces having a plurality of apertures extending from the outer surface of the log to the inner hollow surface of the log;

wherein the plurality of apertures extend the length of the back side and the front side of the log.

15. A toy building set of claim 1 wherein at least two adjacent logs are removably attached by a U connector; wherein a log is stackable with an adjacent log and a U connector is placed on a portion of at least one end of a log and an adjacent log such that the U connector utilizes spring tension on the two adjacent logs and remains removably attached to the logs until desired removal.

16. The toy building set of claim 15, wherein the connector is U shaped and has two ends;

the two ends of the U connector further comprise protrusion that face each other such that the two ends are placed in the hollow of two adjacent logs and the two protrusions are placed in the apertures of the two adjacent logs;

whereby the U connector utilizes spring tension on the two adjacent logs and remains removably attached to the logs until desired removal.

17. The log of claim 2 wherein the log is made of expanded polyethylene foam.

18. The connector of claim 5 wherein the connector is made with injection molded plastic

19. The log of claim 2 wherein the log apertures are shaped as one of the following:

a. circle;

b. two slits forming a plus sign;

c. center circle superimposed on two slits;

d. an oval;

e. or an ellipse.

20. The toy building set of claim 1 further comprising:

a. a spike having a first end with a flat head and a second end with a bulbous detail;

b. the bulbous detail of a spike passing through a log aperture or a plurality of log apertures to the hollow area of a log such that the bulbous detail of the spike forms an interference fit in the aperture of a log and said spike flat head is sized to remain outside of a log.

21. The toy building set of claim 20 further comprising:

a. flat plate fastener having an elongated oval planar shape with a first end having a portal there through and a second end having a portal there through;

b. a spike is passed through a portal of the flat plate fastener and a log apertures to the hollow area of a log such that the bulbous detail of the spike forms an interference fit in the aperture of the log and said spike flat head is sized to remain outside of the portal of the flat plate connector and of the log such that two adjacent logs are connected with apertures not facing each other.

22. A toy building set having a hollow plastic extrusion log and said hollow plastic extrusion log comprising;

a front side and a back side;

a first end and a second end;

a top side and a bottom side;

each top and bottom side having a plurality of apertures in the extending from an outer surface of the log to an inner hollow surface of the log;

wherein the log is stackable by aligning the bottom side of said log with an adjacent top side of a log to thereby construct the desired lightweight self-supporting structure.

23. A toy building set of claim 3 further comprising a fabric having apertures to accept and attach the fabric to a log or plurality of logs.

24. A method of using a toy building set to build play sets comprising the following steps:

a. selecting a plurality of logs, each log comprising; a front side and a back side; a first end and a second end; a top side and a bottom side; each top and bottom side having a substantially flat planar surface; a plurality of apertures in the substantially flat planar surface and the apertures extending from an outer surface of the log to an inner hollow surface of the log; said plurality of apertures extending the length of the top and bottom sides substantially flat planar surface;

b. determining the length of the logs needed for building a toy structure;

c. determining what logs need to be cut;

d. counting the number of apertures on the logs needing to be cut to determine where to cut the logs and sawing the logs to appropriate sizes;

e. placing one of the plurality of logs on the ground or on a support horizontally with on of the substantially flat planar surfaces facing the ground or support;

f. placing a connector or plurality of connectors into the apertures of the log placed on the ground or support;

g. determining which of the plurality of logs is a second log to be placed on top of the log already placed;

h. placing the second log, wherein the second log is stackable on the log already place and connectors are between and inside apertures of adjacent apertures of the logs;

i. wherein this method continues with a plurality of adjacent logs and connectors are placed between and inside apertures of adjacent logs to thereby construct the desired lightweight self-supporting structure.

25. A method of using a toy building set of claim 24 further comprising the following steps:

a. selecting a log and determining the length of the log needed;

b. placing a miter on a flat surface;

c. counting the apertures of the log;

d. placing the log in the miter the correct distance from the end to cut the log;

e. placing a saw in a slot of the miter to accept the saw;

f. saw the log.